This document summarizes an industrial training project to streamline production processes at a manufacturing plant. The project involved: 1. Line balancing and defining hourly outputs to improve efficiency. This included reducing idle operator time and improving formation ratios. 2. Streamlining zigzag product flows to reduce distances and increase output. Changes reduced flow distances by 1.5 meters and cycle times by up to 6 seconds. 3. Analyzing downtimes from issues like material and trolley shortages, and implementing solutions like ensuring all materials for a shift are available. This reduced downtimes. 4. Defining work-in-process inventories between steps to prevent shortages and stabilize the production flow. 5

1. INDUSTRIAL IN-PLANT
TRAINING
UNDER THE GUIDANCE OF-
Mr. M. MAGDUM (D.G.M. Mfg Engg.)
Mr. A. HARISH (A. M. Mfg Engg.)
PROJECT
BY-
AMEYA MARGAJ
PANKAJ KHAIRNAR
AISSMS COE, PUNE-1

2. ACTIVITIES JAN
2012
FEB
2012
MAR
2012
APRIL
2012
MAY
2012
JUNE
2012
FINALIZE PROJECT
GATHER DATA
ANALYSE DATA
SELECT SOLUTION
IMPLEMENT
CLOSURE
 TIMELINE

3. STREAMLINING THE ZIG-ZAG FLOW AND LINE
BALANCING
CONTENTS:
1. Defined hourly outputs for all cells depending upon the
customer requirement (i.e. TAKT Time) and Preparation of
Standardized Work Charts according to Line Balancing .
2. Streamlining the Zigzag Flow.
3. Analysis of Downtimes in Peripheral Assembly.
4. Improvement projects for reducing inventory (i.e. Reducing Cost).
5. Stabilization of process by monitoring and analysis through process
capability (Cp) and process capability index (Cpk) for Critical
Processes.

4. PROBLEMS :-
 Line Balancing
• More operator idle time.
• Improving Human efficiency.
• Less formation ratio.
DATA COLLECTION:-
Line balanced according to the cycle times taken
LINK TO ALL C.T.
LINK TO ONLINE PDI
1. DEFINE STANDARD CYCLE TIMES FOR SBC, ROD CELL,
ASSEMBLY & PDI

5. 12
8 8
0
2
4
6
8
10
12
14
1 2 3
TIME(SEC)
OPERATORS
DIA 22 FR BEFORE
12
16
0
2
4
6
8
10
12
14
16
18
1 2TIME(SEC)
OPERATORS
DIA 22 FR AFTER
LINE BALANCING FOR ONLINE PDI (STRUT LINE ASSY)
 Assembly C.T. = 16sec

6. LINE BALANCING FOR ONLINE PDI (STRUT LINE ASSY)
 Assembly C.T. = 23sec

7. LINE BALANCING FOR ONLINE PDI (NEW LINE ASSY)
 Assembly C.T. = 21 sec

8.  Assembly C.T. = 32 sec
LINE BALANCING FOR ONLINE PDI (NEW LINE ASSY)

9. STREAMLINING THE ZIG-ZAG FLOW AND LINE
BALANCING
CONTENTS:
1. Defined hourly outputs for all cells depending upon the customer
requirement (i.e. TAKT Time) and Preparation of Standardized
Work Charts according to Line Balancing .
2. Streamlining the Zigzag Flow.
3. Analysis of Downtimes in Peripheral Assembly.
4. Improvement projects for reducing inventory (i.e. Reducing Cost).
5. Stabilization of process by monitoring and analysis through process
capability (Cp) and process capability index (Cpk) for Critical
Processes.

10. 2. STREAMLINING THE ZIG ZAG FLOW (IN ASSEMBLY
CELL)
 STRUT LINE: W201 FR (BEFORE)
T
I/T check&
B/v
Pressing
Torquing &
Stacking M/c
Oil Filling
Rod
Guide
press
Damping
Force
Checking
Spinning
Rod
I/T
O/T
T
T
Gas
filling
Striker
Cap
Pressing
Gas
Load
Check
Rod
Assy
Seal
Deflection
M/c
CONVEYOR
PDI
Issues:-
1.Distance
2. Output per shift
3. Quality
Distance : 10.5m

11. I/T
 STRUT LINE: W201 FR (AFTER)
BENEFITS:-
• Distance Reduced by 1.5m
• Cycle time reduced by 6 sec.
• Output per shift increased
by 100 NOS.
• Improved Quality.
Sticker
Cap
Pressing
I/T check&
B/v
Pressing
Torquing &
Stacking M/c
Oil Filling
Rod
Guide
press
Damping
Force
Checking
Spinning
Rod
O/T
T
T T
Gas filling
Gas
Load
Check
Rod
Assy
Seal
Deflection
M/c
CONVEYOR PDI
Distance : 9 m

12. T
STREAMLINING THE ZIG ZAG FLOW(IN STRUT BODY CELL)
KNUCKLE
BKT
PRESSING-1 (PV)
ROBO WELDING
TWO
TORCH
WELDING
LEAK
TESTING
HYDRAULIC
ROLL
MARKING O/T
END
CAP
CRIMPING
PROOF
LOAD
TESTING
 ROBO WELD CELL ( PRESENT)
Distance : 9.44 m
SPRING SEAT
& KNUCKLE
BKT PRESSING -2
Issues:-
1.Distance
2. Output per shift

13.  ROBO WELD CELL ( PROPOSED)
T
KNUCKLE
BKT PRESSING-1 (PV)
ROBO WELDING
TWO
TORCH
WELDING
LEAK
TESTING
HYDRAULIC
ROLL
MARKING O/T
END
CAP
CRIMPING
PROOF
LOAD
TESTING
Distance : 7.92 m
SPRING SEAT
& KNUCKLE
BKT PRESSING -2
BENEFITS:-
• Distance reduced by 1.5 m
• Operator walking time reduced by 3 seconds
• Output per shift will increase
by 23 NOS.

14. STREAMLINING THE ZIG-ZAG FLOW AND LINE
BALANCING
CONTENTS:
1. Defined hourly outputs for all cells depending upon the customer
requirement (i.e. TAKT Time) and Preparation of Standardized
Work Charts according to Line Balancing
2. Streamlining the Zigzag Flow
3. Analysis of Downtimes in Peripheral Assembly
4. Improvement projects for reducing inventory (i.e. Reducing Cost)
5. Stabilization of process by monitoring and analysis through process
capability (Cp) and process capability index (Cpk) for Critical
Processes.

15. 3. ANALYSIS OF DOWNTIMES IN PERIPHERAL
ASSEMBLY
• PROBLEMS:-
1. Material Shortage
2. Trolley Shortage
3. High Downtimes
• DATA COLLECTION:-
1. Monitored line production for complete shift for 3 weeks.
LINK TO DOWNTIME ANALYSIS SHEET.xls

16. • SOLUTIONS:-
o Complete material necessary for one shift provided at once.
o Separate bush fitting machine provided at online PDI.(W201 RR)
BENEFITS-
1) Downtime due to material
shortage reduced.
2) TLT reduced by 0.5 shift
3) Material Travel distance
reduced by 25 m

17. STREAMLINING THE ZIG-ZAG FLOW AND LINE
BALANCING
CONTENTS:
1. Defined hourly outputs for all cells depending upon the customer
requirement (i.e. TAKT Time) and Preparation of Standardized
Work Charts according to Line Balancing
2. Streamlining the Zigzag Flow
3. Analysis of Downtimes in Peripheral Assembly
4. Improvement projects for reducing inventory (i.e. Reducing
Cost)
5. Stabilization of process by monitoring and analysis through process
capability (Cp) and process capability index (Cpk) for Critical
Processes

18. 4. DEFINITION OF WIP IN BETWEEN DIFFERENT
PROCESSES
• PROBLEMS:-
1. Undefined WIP in between rod welding and assembly,
piercing and assembly, autophoretic and assembly,
assembly and PDI.
2. Frequent shortages due to undefined WIP.
• SOLUTION:-
1. Developed an inventory model wherein WIP will be defined
with respect to the process bottleneck cycle time.
2. WIP ALL MSW-ASSY.xlsx
3. Defined area to keep this WIP.

19. STREAMLINING THE ZIG-ZAG FLOW AND LINE
BALANCING
CONTENTS:
1. Defined hourly outputs for all cells depending upon the customer
requirement (i.e. TAKT Time) and Preparation of Standardized
Work Charts according to Line Balancing
2. Streamlining the Zigzag Flow
3. Analysis of Downtimes in Peripheral Assembly
4. Improvement projects for reducing inventory (i.e. Reducing Cost)
5. Stabilization of process by monitoring and analysis through
process capability (Cp) and process capability index (Cpk) for
Critical Processes

20. 5. STABILIZATION OF OIL FILLING PROCESS
• What is Oil Filling Process ??

21. • PROBLEMS
1. Variation in oil quantity.
2. Frequent adjustment of Stopper length.
3. Wastage of oil during set-up confirmation.
SR. NO. READING IN CC WEIGHT
1 225 192
2 226 193
3 226 193
4 226 193
5 228 196
6 228 196
7 228 196
8 228 296
9 230 197
10 205 177
11 205 177
12 230 197
13 230 197
14 230 197
15 230 197
190
195
200
205
210
215
220
225
230
235
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
VW RR(HBK) BEFORE

22.  ANALYSIS:
 SOLUTIONS:
• Time delay program changed
• Play in the piston cylinder arrangement completely eliminated
• Provision of fixed stoppers instead of adjustable ones.
• Time Delay Program not adjusted properly
• Presence of the play in piston cylinder arrangement
• Use of adjustable stoppers as time delay program not
adjusted properly.

23. • PROCESS CAPABILITY
226
227
228
229
230
231
232
233
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
VW RR (HBK) AFTER
VW RR(HBK)
SR. NO. READINGS IN CC WEIGHT
1 230 197
2 230 197
3 230 197
4 228 196
5 230 197
6 230 197
7 230 197
8 230 197
9 230 197
10 230 197
11 232 198
12 232 198
13 230 197
14 230 197
15 230 197

24.  BENEFITS:-
 LINE BALANCING
– Streamlined Process Flows.
– Reduction in number of Operators by 2.
– Human efficiency improvement for W201 FR from 43% to 60%
– Increase in output per shift by 100 nos.
 PROCESS CAPABILITY.
– Quality improvement by process stabilization.
 ANALYSIS OF DOWNTIMES
– Material Shortage time reduced.

25. THANK YOU